OEM 2002 Mercury Sable Intake Manifold

2002 Mercury Sable Intake Manifold Parts Questions & Experts Answers

• Q: How to service and repair the upper intake manifold on 2002 Mercury Sable?

  A: You should start servicing and repairing the upper intake manifold by taking off the air cleaner outlet tube followed by all hoses connected with clamps. Proceed by removing the pin-type retainers followed by the accelerator cable splash shield before disconnecting both the throttle cable and cruise control cable. The service procedure requires detachment of the Throttle Position Sensor (TPS) and Idle Air Control (IAC) valve electrical connectors together with the throttle body stud harness. Remove all vacuum lines connecting to the Exhaust Gas Recirculation (EGR) vacuum regulator and away from the Exhaust Gas Recirculation (EGR) vacuum supply hoses and Positive Crankcase Ventilation (PCV) as well as Evaporative Emissions (EVAP) sections. Uninstall the EGR valve through the following sequence: disconnect its vacuum hose, take out both nuts and bolts from the valve and then remove the valve itself from the engine. The following procedure requires removing the EGR Vacuum Regulator (EVR) valve by disconnecting both vacuum hose and electrical connector then removing the bolts. Next in the replacement process remove eight upper intake manifold bolts before discarding gaskets while cleaning all mating surfaces. Start by setting new gaskets onto the upper intake manifold and proceed with installing the manifold bolts step by step. The EGR vacuum regulator valve requires placement while bolts get installed after which the electrical connector gets connected and vacuum hose attachment completes the installation process. The EGR valve installation requires users to place it before they bolt it down using both bolts and nuts and attach the vacuum line. First attach the PCV and EVAP vacuum hoses and afterward join the EGR vacuum regulator valve to the vacuum supply hoses. Complete the procedure by first connecting the throttle body stud harness followed by TPS and IAC valve electrical connectors then throttle cable and cruise control cable. Position and install the air cleaner outlet tube using clamps and hoses before you complete the process by installing the pin-type retainers and accelerator cable splash shield.